U.S. patent application number 10/728209 was filed with the patent office on 2004-06-24 for concrete-based floors and wall coverings with an antimicrobial effect.
This patent application is currently assigned to CEMEX TRADEMARKS WORLDWIDE, LTD.. Invention is credited to De Leon Guajardo, Delia, Ramirez Tobias, Homero.
Application Number | 20040121140 10/728209 |
Document ID | / |
Family ID | 32322477 |
Filed Date | 2004-06-24 |
United States Patent
Application |
20040121140 |
Kind Code |
A1 |
Ramirez Tobias, Homero ; et
al. |
June 24, 2004 |
Concrete-based floors and wall coverings with an antimicrobial
effect
Abstract
A concrete-based floor or coating with anti-microbial effect,
comprising a base material and an effective amount of at least one
microbicide organic agent, mixed directly with the base material is
described; the base material is a mixture containing cement, fine
aggregates, solid aggregates, additives and water; where the
microbicide agent mixed with the base material provides an
efficient and long lasting anti-microbial effect.
Inventors: |
Ramirez Tobias, Homero;
(Monterrey, MX) ; De Leon Guajardo, Delia;
(Monterrey, MX) |
Correspondence
Address: |
LEYDIG VOIT & MAYER, LTD
TWO PRUDENTIAL PLAZA, SUITE 4900
180 NORTH STETSON AVENUE
CHICAGO
IL
60601-6780
US
|
Assignee: |
CEMEX TRADEMARKS WORLDWIDE,
LTD.
Brugg
CH
|
Family ID: |
32322477 |
Appl. No.: |
10/728209 |
Filed: |
December 4, 2003 |
Current U.S.
Class: |
428/312.4 |
Current CPC
Class: |
A61P 31/00 20180101;
C04B 2111/60 20130101; C04B 28/02 20130101; C04B 28/02 20130101;
C04B 28/02 20130101; C04B 28/02 20130101; C04B 2111/00482 20130101;
Y10T 428/249968 20150401; C04B 28/02 20130101; C04B 24/40 20130101;
C04B 40/0259 20130101; C04B 40/0259 20130101; C04B 2103/67
20130101; C04B 40/0259 20130101; C04B 40/024 20130101; C04B 40/024
20130101; C04B 24/02 20130101; C04B 40/024 20130101; C04B 24/121
20130101; C04B 40/024 20130101; C04B 40/0259 20130101 |
Class at
Publication: |
428/312.4 |
International
Class: |
B32B 003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 10, 2002 |
MX |
PA/A/2002/012236 |
Claims
1.- Concrete-based floors and wall coverings with anti-microbial
effect, made on a concrete basis, wherein they comprise a base
material and an effective amount of at least one microbicide
organic agent that provides an efficient and long lasting
effect.
2.- Concrete-based floors and wall coverings with anti-microbial
effect, made on a concrete basis, according to claim 1, wherein
said at least one microbicide agent forms an integral part of the
mixture used for floors and wall coverings manufacturing.
3.- Concrete-based floors and wall coverings with anti-microbial
effect, made on a concrete basis, according to claim 2, wherein
said base material comprises from about 5 to approximately 50% by
weight of cement, up to approximately 50% by weight of fine
aggregates, from about 20 to approximately 30% by weight of solid
aggregates, from about 0.01 to approximately 5% by weight of
additives, and where the microbicide agent is present in an amount
of about 0.01% to 5% by weight of the base material.
4.- Concrete-based floors and wall coverings with anti-microbial
effect, made on a concrete basis, according to claim 2, wherein
said microbicide organic agent is selected from a group consisting
of derivatives of phenol, organotins, sodium o-phenylphenate
tetrahydrate or alkyldimethyl benzylammonium chloride or a mixture
thereof.
5.- Concrete-based floors and wall coverings with anti-microbial
effect, made on a concrete basis, according to claim 4, wherein
said phenol derivatives are preferably derived from
2,4,4'-trichlorine-2'-hydroxyphen- ol, and said organotin is
preferably butyl-tin maleate.
6.- A method to manufacture floors and wall coverings with
anti-microbial effect of the type that comprises: a) dose ratio a
base material comprised of cement, fines aggregates, solid
aggregates, additives and water, on the adequate ratios according
to the resistance design required for the application that will be
given to the floor or coating; b) mixing base material components
to form an homogenous paste; c) pouring homogeneous paste in
adequate shape and size moulds according to the floors and wall
coverings design; d) pressing the homogeneous paste contained in
the moulds to eliminate the water excess and obtain a dewatered
paste with the adequate density and porosity; e) the frame
disassembly dewatered homogenous paste from the mould; f) curing
the dewatered homogenous paste under at an environment temperature
during 48 hours or through the use of water vapor during 24 hours
to obtain a concrete-based, cured floor or coating; g) calibrating
the cured floor or coating to boast and shape its dimensions; and
h) polishing and brightening concrete-based floor or coating;
wherein it comprises a further step of adding an effective amount
of at least one microbicide agent before the step b.
7.- The method of manufacturing floors and wall coverings with
anti-microbial effect according to claim 6, wherein said at least
microbicide agent forms an integral part of the paste used for said
floors and wall coverings manufacturing.
8.- The method of manufacturing floors and wall coverings with
anti-microbial effect according to claim 7, wherein said effective
amount of the microbicide agent will depend on the use and
environmental conditions of the place on which the concrete-based
floor or coating will be applied; to prevent a bacteria or
microorganisms adhesion growth and spreading out upon said floors
and wall coverings surfaces.
9.- The method of manufacturing floors and wall coverings with
anti-microbial effect according to claim 8, wherein said effective
amount of the microbicide agent will range from 0.01% to 5% by
weight of the base material.
Description
FIELD OF THE INVENTION
[0001] The present invention is related to construction materials
having anti-microbial effect. More particularly, the present
invention is related to floors and wall coverings made of cement,
aggregates and additives, having effective and lasting
anti-microbial effect.
BACKGROUND OF THE INVENTION
[0002] Microbes control is a major concern on a wide variety of
fields encompassing home living and several industries. For
example, contamination or lack of hygiene on floors, walls and
ceilings at homes is a microbial infection source under
considerable moisture conditions within an enclosed room.
[0003] In the food industry, contamination with microorganisms in
several stages such as: products manufacturing, processing and
packing, is a serious problem from the point of view of food
sanitation and preservation. In such case, the main microbial
infection source is an environment contaminated by microorganisms
that adhere and grow upon the room walls, ceilings and floors,
where food manufacturing, processing and packing is carried out;
this contaminating microorganisms may have the chance to spread out
and contaminate the food.
[0004] Within the field of medical services, there exist strong
demands for a biologically sanitized room as a measure against
infections, due to an adverse environmental contamination of the
surgery room, treatment room, examination room, patients room,
waiting room, clinic, kitchen, etc. In this case, protecting walls,
ceiling and floors against microbes attack and growth, represents a
serious problem.
[0005] It is very important that medicines and drugs are produced
within a microorganisms-free neat environment.
[0006] Within the field of the electronics industry, it is also
acknowledged that manufacturing electronic components within a
microbiologically neat environment is beneficial to improve
electronic parts or components functioning, accuracy, reliability
and production. Further, it is also important to prevent that
bacteria and fungi adhere and grow on walls, ceilings and
floors.
[0007] Conventional measures against contamination by
microorganisms include: i) surface cleaning such as: room, area or
ward floors, walls and/or ceilings, with cleaning agents such as
detergent, bleach, etc., which shall be regularly carried out at
relatively short periods; ii) applying a microbicide agent to the
surface, which represents the disadvantage of having a sustained
action and short period of the agent applied; and iii) applying a
coating material incorporating a microbicide agent that is applied
on the floor, wall and/or ceiling surface, coating material may be
applied in the form of a layer, film or sheet.
[0008] Nowadays, a plurality of microbicide agents that can be used
alone or combined to avoid microbe adhesion and spreading at homes
and several industries surfaces has been developed. These
microbicide agents can be mixed for example with cleaning products,
compositions and disinfectants, or being applied as wall coverings
on fabrics, paper, adhesive strips, plastic materials sheets,
etc.
[0009] A particular example of the efforts made on the art is
disclosed by the U.S. application Ser. No. 4,008,351 entitled
"Sheet or film material having antibacterial and anti-fungal
activity", issued on Feb. 15, 1977 to Mayumi et al, which discloses
a sheet or film material having antibacterial and anti-fungal
activity utilized to cover walls, ceiling and floors. Said material
is obtained by mixing a benzimidazole and phtalimide. Such sheet or
film material disclosed by said application is a thermoplastic
material based product, and even that can provide a protection
against microbial growth, it has the disadvantages of being an
additional component which is submitted to wearing due to use and
can be coated or replaced at the short run with the additional
expenses entailed. This application does not suggest that
microbicide agents can be an integral part of cement and aggregates
based composition. Equally, making a long lasting product, such as
floor or coating having a lasting anti-microbial effect, is not
suggested.
[0010] U.S. application Ser. No. 6,162,845 entitled "Reinforced
Concrete having Improved Anti-microbial Fibers", issued on Dec. 19,
2000, to W. Wayne Freed, discloses a material product similar to
concrete reinforced with fibers having an effective amount of a
microbicide agent incorporated therein, to prolong concrete
duration, where the microbicide agent is provided incorporated in
or coating a plurality of fibers, which, in turn, are spread within
a concrete matrix. Fibers inclusion with a microbicide agent is
aimed to reinforce concrete and reduce concrete sensitivity to a
biological attack. However, this document is referred to the fiber
reinforced concrete specific application, whose fiber includes a
microbicide agent (Microban.RTM. B) that protects concrete itself
from deterioration due to microorganisms growth, this concrete is
used for the construction of entire buildings and specially those
in which an additional protection due to the use of this kind of
agents is required. However, reference is not made to
concrete-based floors and wall coverings in different forms and
designs, that do not include a fiber as a reinforcement element and
as a carrier for incorporating a microbicide agent, for the
anti-microbial protection when being utilized as a floor and
coating for walls and ceilings without the need of the entire
building construction with such products. Also, there is no
reference made of a finished product for specific use, having
proved long lasting anti-microbial action using microbicide agents
without including a fiber as a carrier.
[0011] U.S. application Ser. No. 6,350,350 entitled "Construction
Material", issued on Feb. 26, 2002 to Eisaku Tozaka, discloses a
construction material containing microcapsules of a specific
bactericide agent, mixed with a basic construction material such as
cement, aggregates and water mixture. Said basic material with the
bactericide agent microcapsules is used for floors, walls and
ceilings construction. The liquid bactericide agent contained in
the microcapsules is gradually perspired or infiltrated into the
construction material each time microcapsules break due to a change
over time. The construction material with an antibacterial action
of the present invention presents the disadvantage of requiring
further devices and processes for first forming the microcapsules
containing the specific microbicide agent, and after having
obtained this microcapsules, are incorporated with the mixture to
finally form the construction material. Another disadvantage of
this construction material is the cost factor entailed when being
used to build walls and construction in general, to provide the
protection mentioned above. However, there is no suggestion on said
application, that the microbicide agent be directly integrated as
another component of the construction material, and including an
immediate and long lasting anti-microbial action, this is, without
using a carrier such as microcapsules.
[0012] There are other publications and applications that
incorporate several additives being mixed with concrete or a
construction material, or being disposed as a coating on said
concrete or construction material. For example, Russian application
No. 2149147, entitled "Agglomerating Agent" to Sycheva et al.,
published on May 20, 2000 discloses the preparation of solutions
and concretes under low temperatures showing an antibacterial
activity by the incorporation of KmnO.sub.4 to a ratio of 0.1 to
0.3% by weight. The use of KmnO.sub.4 as a microbicide compound
shows the disadvantage of providing a particular coloration to the
concrete, preventing the production of several products with
different colors. Besides, due to said coloration provided by
KmnO.sub.4, its application on floors and ceilings and walls wall
coverings is very limited.
[0013] Japanese application No. 11236734 entitled "Antibacterial
Construction Material" to Miyasaki Norihiko published on Aug. 31,
1999, discloses an ultra-violet curing type antibacterial coating
composition for interiors finishing, such as a floor, wall or
ceiling; where the antibacterial coating composition is a
painting-type composition comprising a base resin and amino acid
salt of an antibacterial metal. This kind of wall coverings show
the disadvantage of metal-based products used for providing the
antibacterial effect, such metal-based products present problems,
as its handling and application to form small layers or protective
films is concerned. For the particular case that is used as a
coating for a floor, said coating is worn or removed due to simple
use, being necessary to prepare again the floor to apply the
antibacterial coating composition once again.
[0014] Chinese application No. 1223795 entitled "Bactericide
Additive for Construction, its Preparation Method and Use" to Tian
Shulin, published on Jul. 28, 1999, discloses a bactericide
additive for construction materials which is prepared from a
carrier and antibacterial metal salt. This document shows the
disadvantage that additional stages and materials for manufacturing
and adequate bactericide additive that can be used for the
construction industry are required. However, it is not mentioned
that said active component could be directly used for preparing
concrete-based elements (for example, floors, walls, and ceilings
coating) keeping its microbicide properties and sustaining a long
lasting effect.
[0015] Japanese application No. 4331752 entitled "Antibacterial and
Anti-fungal Basic Material for Construction" to Nawata Nozomi et
al., published on Nov. 19, 1992 is referred to the addition of 0.01
to 30 parts by weight of an antibacterial and anti-fungal compound,
such as 2,2,3-thioyodineallyl alcohol added to the base material
(cement or plaster). The antibacterial and anti-fungal compound can
be mixed with a base material, where the base material is in
powder, not molded or not cured yet; this antibacterial and
anti-fungal compound is applied to the base material surface
through the recoating or spraying method. This Japanese application
describes a product with an antibacterial and anti-fungal action
which is used to coat with small layers the elements desired to be
protected; however, it does not suggest the use of a microbicide
agent in an integral form of the concrete-based element used on
floors, walls, and ceilings wall coverings, etc., which has a long
lasting anti-microbial effect and which does not require any
further protecting layers for protecting the surface.
[0016] Japanese application No. 8109108 entitled "Construction
material having an antibacterial activity consisting of a combined
material obtained by using mordenite and its production" to Ogura
Ywsuke et al., published on Apr. 30, 1996, discloses a material
that comprises a carrier made from mordenite (main component) that
is immersed in a diluted solution of silver nitrate, where an
alkaline ion is displaced with a silver ion. The carrier is in
combination with a construction material, such as cement, wood,
chips, paper or fibers to obtain a combined material. This combined
material is formed and processed desirably as a construction
material. This material is useful indoors as well as outdoors. This
Japanese application is related to a material for general
construction, which includes a further step of soaking one of its
components with the antibacterial agent solution to displace one
alkaline ion with a silver ion, however, it is not mentioned that
the agent can be directly added without the use of a carrier to
dose the microbicide agent, avoiding the use of heavy metal based
compounds and the need of additional steps, providing an efficient
and long lasting anti-microbial effect.
[0017] According to the above mentioned, there is no document
registered that describes or suggests a concrete-based floor or
coating not requiring additional materials or carriers and
procedures to directly incorporate the microbicide agent as a
component of the concrete-based floors and wall coverings
composition. Consequently, there is a need for useful
concrete-based floors and wall coverings for applications where a
more hygienic environment is required, that comprises at least an
organic microbicide agent being readily mixed directly, and with
fast and long lasting release of the active agent on its surface,
to inhibit microbial growth.
[0018] Therefore, it is an objective of the present invention to
provide common manufactured concrete-based floors and wall
coverings, and at the same time exhibit an efficient and long
lasting anti-microbial effect.
[0019] Another objective of the present invention is to provide at
least one microbicide agent as a cement component, aggregates and
additives mixture, for manufacturing finished floors and wall
coverings ready to be installed.
[0020] Still another objective of the present invention is to
provide concrete-based floors and wall coverings with efficient
inhibition of microorganisms growth and contact, to be used in
areas such as homes, several industries, food processing plants,
pharmaceutical labs, hospitals, etc., which require extraordinary
cleanliness.
[0021] Still a further objective of the present invention is to
provide a low cost finished product of the type of a concrete-based
floor and/or coating with anti-microbial effect that will not
require the use of carriers to be incorporated into a base material
without special mechanisms for its release.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Generally, the present invention is related to a floor
and/or coating with an anti-microbial effect, being concrete-based
manufactured and which includes at least a microbicide agent that
provides an efficient and long lasting effect.
[0023] In one embodiment of the invention, the concrete-based floor
and/or coating with anti-microbial effect comprises a base material
and an effective amount at least of a microbicide organic agent
mixed directly with the base material. The base material is a
mixture comprising cement, fine aggregates, solid aggregates,
additives and water.
[0024] In another aspect of the invention, the floor and/or coating
base material comprises from about 5 to approximately 50% by weight
of cement, up to approximately 50% by weight of fine aggregates,
from about 20 to approximately 30% by weight of solid aggregates,
from about 0.01 to approximately 5% by weight of additives, and
where a 0.01% to 5% by weight of a base material of at least one
microbicide agent or a mixture of microbicide agents is added.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] As mentioned before, the present invention is related to a
concrete-based floor and/or coating which includes an effective
amount at least of a microbicide agent or a mixture of microbicide
agents to inhibit biological attack and spreading out of
organisms.
[0026] The present invention is a concrete-based construction
material for finishes such as a floor and/or coating having an
immediate anti-microbial effect. The concrete-based construction
material for finishes comprises a base material and an effective
amount at least of a microbicide organic agent or a mixture of
various microbicide organic agents being directly mixed with the
base material. The base material is a mixture comprising cement,
fine aggregates, solid aggregates, additives and water. In a
preferred embodiment of the present invention, the base material
comprises from about 5% to approximately 50% by weight of cement,
up to approximately 50% by weight of fine aggregates, from about 20
to approximately 30% by weight of solid aggregates, from about 0.01
to approximately 5% by weight of additives.
[0027] Useful microbicide agents in the present invention are
organic, non-toxic, and environmentally save during their use. As
it is known, most of microbicide agents control the organisms
growth by penetrating the organism thin cellular walls, thereby
interrupting the organism metabolic function, and finally killing
said organism. In this way, it shall be understood in the present
invention that the term "microbicide agent" refers to including any
organic compound that effectively inhibits a microbial attack and
its spreading out on a concrete-based finished floor or coating.
The term "at least one microbicide agent" as used in the present
invention, should be understood as been feasible to use a
microbicide agent or a mixture of different microbicide agents.
[0028] Proper microbicide agents to be used by the present
invention are derivatives from phenol, especially
2,4,4'-trichlorine-2'-hydroxyphenol (for example, Triclosan,
irgasan, microban), organotins, especially butyl-tin maleate (for
example, Ultra Fresh), sodium o-phenylphenate tetrahydrate
(Dowcide-A), and alkyldimethyl benzylammonium chloride.
[0029] Dose ratio for adding microbicide agents to the base
material used by the present invention varies significantly
depending on the use and environmental conditions of the place on
which the concrete-based floor or coating will be applied.
Therefore, an effective amount of a microbicide agent to prevent
bacteria and microorganisms adhesion, growth and spreading out at
homes and several industries surfaces is required. In most of the
cases, the effective ratio of the microbicide agent or the mixture
of microbicide agents will range from 0.01% to 5% by weight of the
base material.
[0030] A preferred method to add at least a microbicide agent is
simply mixing the microbicide agent along with the base material
components, this is, cement, fine aggregates, solid aggregates,
additives and water, through conventional means well known in the
state of the art. There for, a concrete mixture with anti-microbial
effect is obtained, which is subsequently submitted to a
manufacturing procedure to form a floor and/or coating.
[0031] An illustrative manufacturing method to form a floor and
coating comprises the following steps:
[0032] 1) Dose ratio.--Base material ingredients or components at
an adequate ratio, being according to the required resistance
design by the application that shall be given to the element, are
dosed along with an effective amount of at least one microbicide
organic agent, depending on the anti-microbial effect desired. Main
base material compounds are cement, fine aggregates, solid
aggregates, (marble and granite pieces, etc.), dyes and water.
[0033] 2) Mixing or kneading.--Once the base material and the
microbicide agent being dosed, these are mixed or kneaded, through
any appropriate method or device known in the art, to obtain a
homogeneous paste with anti-microbial effect and properly integrate
the base material ingredients and the microbicide agent.
[0034] 3) Moulds refilling.--An adequate amount of previously
homogenized paste with anti-microbial effect is dosed and refilled
to the moulds, which can have several forms and sizes according to
the floors and wall coverings design (rectangular, curved,
etc.).
[0035] 4) Pressing.--The paste previously poured into the moulds is
submitted under pressure application, through a press, for the
paste to eliminate water excess and to obtain a product with the
adequate density and porosity to be handled by the machinery for
subsequent stages.
[0036] 5) Curing.--Once the product is hardened through the
pressing stage, floors and wall covering frames are disassembled,
and taken to the curing room; the latter can be made under normal
temperature, which will last 48 hours or by using vapor, through
which time is reduced to 24 hours.
[0037] 6) Calibration.--Once floor tiles have been set and acquired
a resistance through the curing stage, their dimensions are
calibrated by using surfacing and shaping machines perfectly
aligned.
[0038] 7) Polishing and brightening.--After calibration, floors and
wall coverings pass through polishing and brightening line, which
comprises multiple grindstones which boast, abrade, polish and
brighten the above.
[0039] 8) Packing.--final product is packed in multiple
presentations.
EXAMPLE
[0040] In order to show the practice of the invention and evaluate
the efficacy thereof, a base material is prepared by mixing 25% by
weight of cement, 50% by weight of fine aggregates, 24.5% by weight
of solid aggregates (marble pieces), and water in a sufficient
amount to form a mixture. During base material mixture forming, a
microbicide agent of 0.05% by weight (Triclosan) is added and
homogeneously mixed with the entire mixture of base material,
forming thereby a base material with anti-microbial effect. Then,
the mixture with anti-microbial effect is poured in a mould with
adequate shape and dimensions in order to form a concrete floor
tile.
[0041] After the floor tile with anti-microbial effect has been
cured, a sample of approximately 25 mm of diameter (treated
element) is taken to prove the anti-microbial inhibition along with
the floor tile made with a non-treated conventional material
(element of control). Test results are shown in table 1 below.
1 TABLE 1 Control Treated Inhibition Microorganism element element
zone Escherichia coli Growth No growth 5 mm Staphilococus Growth No
growth 17 mm aureus Enterobacter Growth No growth 5 mm
aerogenes
[0042] As it can be seen from table 1, the inhibition zone around
test tubes treated with the microbicide agent (Triclosan in this
case) shows the effect the elements have when treated to inhibit
microorganisms growth and reproduction, in other tests, the growth
inhibitor effect that this kind of treatment has on fungi, has also
been shown. This shows the protecting capacity these concrete-based
floors and wall coverings have to contribute for the protection of
microorganisms spreading out on places where they have been
used.
[0043] Even though certain embodiment of the invention has been
illustrated and described, it should be noted that several changes
and modifications could be made there on. There for, the present
invention shall not be considered as limited excepting by what the
prior art demands and by the spirit of claims attached herein.
* * * * *